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EP3870353B1 - Procédé et réacteur pour la conversion d'hydrocarbures - Google Patents

Procédé et réacteur pour la conversion d'hydrocarbures Download PDF

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Publication number
EP3870353B1
EP3870353B1 EP19877101.6A EP19877101A EP3870353B1 EP 3870353 B1 EP3870353 B1 EP 3870353B1 EP 19877101 A EP19877101 A EP 19877101A EP 3870353 B1 EP3870353 B1 EP 3870353B1
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Prior art keywords
reactor
gas
feed
downstream
upstream
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EP19877101.6A
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German (de)
English (en)
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EP3870353A4 (fr
EP3870353A2 (fr
Inventor
Byeongjin BAEK
Lei Chen
Vladimir SHTERN
Istvan Lengyel
David West
Krishnan Sankaranarayanan
Sreekanth Pannala
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SABIC Global Technologies BV
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SABIC Global Technologies BV
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Priority to EP24179108.6A priority Critical patent/EP4400563A3/fr
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Publication of EP3870353A4 publication Critical patent/EP3870353A4/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B01J19/2455—Stationary reactors without moving elements inside provoking a loop type movement of the reactants
    • B01J19/246—Stationary reactors without moving elements inside provoking a loop type movement of the reactants internally, i.e. the mixture circulating inside the vessel such that the upward stream is separated physically from the downward stream(s)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J12/00—Chemical processes in general for reacting gaseous media with gaseous media; Apparatus specially adapted therefor
    • B01J12/005—Chemical processes in general for reacting gaseous media with gaseous media; Apparatus specially adapted therefor carried out at high temperatures, e.g. by pyrolysis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0053—Details of the reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0053—Details of the reactor
    • B01J19/006—Baffles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/02—Apparatus characterised by being constructed of material selected for its chemically-resistant properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B01J19/2405—Stationary reactors without moving elements inside provoking a turbulent flow of the reactants, such as in cyclones, or having a high Reynolds-number
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B01J19/2415—Tubular reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J4/00—Feed or outlet devices; Feed or outlet control devices
    • B01J4/001—Feed or outlet devices as such, e.g. feeding tubes
    • B01J4/005—Feed or outlet devices as such, e.g. feeding tubes provided with baffles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J6/00—Heat treatments such as Calcining; Fusing ; Pyrolysis
    • B01J6/008—Pyrolysis reactions
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2/00—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms
    • C07C2/54—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition of unsaturated hydrocarbons to saturated hydrocarbons or to hydrocarbons containing a six-membered aromatic ring with no unsaturation outside the aromatic ring
    • C07C2/56—Addition to acyclic hydrocarbons
    • C07C2/58—Catalytic processes
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
    • C07C5/42—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with a hydrogen acceptor
    • C07C5/48—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with a hydrogen acceptor with oxygen as an acceptor
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G9/34—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts
    • C10G9/36—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts with heated gases or vapours
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
    • C10G9/34—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts
    • C10G9/36—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts with heated gases or vapours
    • C10G9/38—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils by direct contact with inert preheated fluids, e.g. with molten metals or salts with heated gases or vapours produced by partial combustion of the material to be cracked or by combustion of another hydrocarbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2204/00—Aspects relating to feed or outlet devices; Regulating devices for feed or outlet devices
    • B01J2204/002—Aspects relating to feed or outlet devices; Regulating devices for feed or outlet devices the feeding side being of particular interest
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/00074—Controlling the temperature by indirect heating or cooling employing heat exchange fluids
    • B01J2219/00087—Controlling the temperature by indirect heating or cooling employing heat exchange fluids with heat exchange elements outside the reactor
    • B01J2219/00094—Jackets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00761—Details of the reactor
    • B01J2219/00763—Baffles
    • B01J2219/00765—Baffles attached to the reactor wall
    • B01J2219/0077—Baffles attached to the reactor wall inclined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/19—Details relating to the geometry of the reactor
    • B01J2219/194—Details relating to the geometry of the reactor round
    • B01J2219/1941—Details relating to the geometry of the reactor round circular or disk-shaped
    • B01J2219/1943—Details relating to the geometry of the reactor round circular or disk-shaped cylindrical

Definitions

  • the invention relates to conversion methods for converting a variety of hydrocarbons to produce more valuable products and the reactor designs for such conversion.
  • a single-stage combustion pyrolysis method to produce acetylene was developed by BASF, which is described in U. S. Patent No. 5,789,644 .
  • This process has been commercialized at a 50 KTA scale using multiple reactors in Germany and the U.S.
  • natural gas serves for the hydrocarbon feed
  • pure oxygen serves as the oxidant to generate heat, which is critical for acetylene production.
  • the two streams are premixed in a diffuser, and the premixed fuel rich gas is burnt using a burner block through partial oxidation.
  • a major disadvantage of such a design is the flashback risks of the premixed flame under various feedstock and operating conditions, as well as the plurality of burners used, which increases the total cost of operation, difficulties in heat control, and low carbon yield toward olefin product.
  • acetylene used to be the building block for chemicals over the last six to seven decades olefins have become the building blocks of the chemical industries and there is a desire to directly produce olefins rather than the indirect hydrogenation route using acetylene.
  • Conventional steam crackers are the industry go-to reactors to break long-chain hydrocarbons and modify smaller alkanes (i.e., naphtha, butane, ethane) into smaller molecules and olefins, such as ethylene and propylene.
  • alkanes i.e., naphtha, butane, ethane
  • olefins such as ethylene and propylene.
  • heavy gases such as naphtha, liquefied petroleum gas (LPG), propane, butane, and ethane are fed into a furnace with steam and converted into smaller olefins.
  • Steam is added to the process to increase the selectivity to olefins with reasonable conversion.
  • this process operates at high temperatures (i.e., from 750 °C to 900 °C) and has residence times of around 100 to 500 milliseconds.
  • a gas turbine engine fuel injection apparatus comprises a fuel spray atomiser which directs a fuel spray on to the radially inner surface of an annular flow deflector.
  • the fuel flows in a film over the flow deflector surface towards an annular lip at the downstream end of the deflector. Swirling air flows are directed over the radially inner and outer surfaces of the flow deflector so as to atomise the fuel as it leaves the annular lip.
  • the fuel is evaporated in the swirling airflows and thoroughly mixed with the airflows in a mixing duct before being discharged into a combustion chamber.
  • the thorough mixing of the evaporated fuel and the airflows prior to combustion results in the production of reduced quantities of the oxide of nitrogen.
  • the region externally of the fuel injection apparatus is at high pressure and, air flows through inlets which have swirl vanes to impart a swirling motion to the air.
  • EP 3 336 432 A1 discloses a nozzle including a nozzle body with an inner air passage fed by a first radial swirler and a second radial swirler axially downstream of the first radial swirler.
  • a first fuel circuit is axially between the first and second radial swirlers.
  • a second fuel circuit is axially downstream of the second radial swirler, wherein each of the first fuel circuit and the second fuel circuitextends from a respective fuel circuit inlet to a respective annular fuel circuit outlet.
  • An outer air passage is defined between a fuel circuit outer wall of the second fuel circuit and an outer air passage wall, wherein the outer air passage is a converging non-swirling air passage.
  • the proposed invention addresses many of the shortcomings of these conventional reactors.
  • the invention is directed to a reactor system according to claim 1.
  • At least one of the annular inlet flow spaces is provided with circumferentially spaced apart guide vanes oriented to facilitate the swirling fluid flow within said at least one of the inlet flow spaces.
  • the guide vanes may be movable to selected positions and tilting angles to provide selected azimuthal-to-radial velocity ratios of fluids flowing within the annular inlet flow spaces.
  • the guide vanes are configured as non-planar airfoils.
  • the reactor wall is cylindrical.
  • the circumferential wall of the converging conduit from the downstream end to the annular constricted neck portion, and optionally an upstream portion of the reactor wall of the reaction chamber that joins the circumferential wall of the converging conduit, may be configured as a smooth, continuous wall that follows contour lines of an ellipsoidal cap or spherical cap shape.
  • the interior of the reactor wall may be a refractory material.
  • the downstream gas partition wall has an extended portion that is spaced from and follows the contours of the circumferential wall of the converging conduit of the reactor inlet assembly and terminates at a position downstream of the annular constricted neck portion so that a downstream inlet flow space is defined that discharges into an area downstream from the constricted neck portion.
  • the intermediate annular gas inlet flow space is divided by an intermediate gas partition wall having a central opening that surrounds the central axis of the converging conduit and divides the intermediate inlet flow space into upstream and downstream intermediate annular inlet flow spaces that constitute inlet flow spaces for introducing a fuel gas feed and an oxidizer feed.
  • the upstream annular gas inlet flow space and the intermediate inlet flow space constitute inlet flow spaces for introducing a fuel gas feed and an oxidizer feed.
  • a cooling gas feed assembly is in fluid communication with at least one of the reaction chamber and the reactor inlet assembly.
  • the cooling gas feed assembly includes a pair of axially spaced apart cooling gas feed assembly walls oriented perpendicular or substantially perpendicular to the central axis.
  • An annular cooling gas inlet flow space is defined between the cooling gas feed assembly walls and communicates with said at least one of the reaction chamber and the reactor inlet assembly.
  • the annular cooling gas inlet flow space may be provided with circumferentially spaced apart guide vanes oriented to facilitate the swirling fluid flow within the cooling gas inlet flow space.
  • the invention is also directed to a method of converting hydrocarbons to olefins, according to claim 8.
  • the fuel gas feed which may comprise a hydrogen-containing gas of at least one of hydrogen gas (H 2 ) and methane (CH 4 ), is introduced into one of the first and second annular fuel gas inlet flow spaces.
  • An oxidizer feed which comprises an oxygen-containing gas, is introduced into the other of the first and second annular fuel gas inlet flow spaces.
  • the hydrogen-containing gas may be introduced into the feed assembly to provide an excess of hydrogen that is from 1 to 5 times that required for cracking the hydrocarbon feed
  • the cracking feed may include at least one of ethane, liquefied petroleum gas, butane, naphtha, natural gas, light gas oils, and heavy gas oils, the cracking feed optionally being premixed with steam.
  • At least one of hydrogen gas (H 2 ), methane, and carbon oxides or combinations thereof may be separated from the removed cracked hydrocarbon product and recycled to the feed assembly.
  • the azimuthal-to-radial velocity ratio of each of the feeds and the oxygen gas feed stream within the annular flow spaces may be from 0 to ⁇ , more particularly from 0 to 30.
  • Each of the feeds may each be introduced into the respective annular flow spaces in the same rotational direction.
  • at least one of the annular inlet flow spaces is provided with circumferentially spaced apart guide vanes oriented to facilitate the spiraling fluid flow within said at least one of the inlet flow spaces.
  • the guide vanes may be movable to selected positions and tilting angles to provided selected azimuthal-to-radial velocity ratios of the fluid flow within said at least one of the inlet flow spaces.
  • the reactor wall is cylindrical.
  • the circumferential wall of the converging conduit from the downstream end to the annular constricted neck portion, and optionally an upstream portion of the reactor wall of the reaction chamber that joins the circumferential wall of the converging conduit, may be configured as a smooth, continuous wall that follows contour lines of an ellipsoidal cap or spherical cap shape.
  • the interior of the reactor wall may be a refractory material.
  • the residence time of the gas mixture within the reactor system is 50 milliseconds or less in certain instances.
  • the reaction conditions may include a temperature of from 900 °C to 1300 °C and a pressure of from 0 kPa (g) to 10,000 kPa (g) at an outlet of the reactor.
  • the reactor system further comprises a cooling gas feed assembly in fluid communication with at least one of the reaction chamber and the reactor inlet assembly.
  • the cooling gas feed assembly comprises a pair of axially spaced apart cooling gas feed assembly walls oriented perpendicular or substantially perpendicular to the central axis.
  • An annular cooling gas inlet flow space is defined between the cooling gas feed assembly walls that communicates with said at least one of the reaction chamber and the reactor inlet assembly where cooling gases from the cooling gas feed assembly are introduced.
  • a novel system that converts hydrocarbons to higher value products, such as olefins, by utilizing high centrifugal forces generated by swirling flow in a unique reactor configuration to create and control a reacting flow environment that maximizes the production of desirable olefins with very high productivity (cracking).
  • This is achieved by utilizing annular highly swirled jets of feed gases where hydrogen (or other fuels such as natural gas, recycled syngas, etc.) and oxygen gases are mainly used to generate the heat required for cracking of hydrocarbons.
  • the cracking reactor used is similar to the pyrolysis reactor described in U.S. Patent Publication No. 2021046440 .
  • 2021046440 describes a reactor that can be used in the pyrolysis conversion of hydrocarbon gases.
  • This type of reactor may be referred to as an ANJEVOC (ANnular JEt VOrtex Chamber) reactor.
  • the ANJEVOC reactor described herein, while similar to that described in U.S. Patent Publication No. 2021046440 is used for cracking and therefore is configured differently.
  • Such reactor may be referred to as the ANJEVOC-C (ANnular JEt VOrtex Chamber - Cracking) reactor.
  • the system 10 includes an ANJEVOC-C cracking reactor 12, which is described in more detail later on.
  • a cracking feed 14 is fed to the reactor 12 as a separate stream.
  • the cracking feed 14 can include hydrocarbons such as ethane, liquefied petroleum gas (LPG), butane, naphtha, natural gas, light gas oils, and/or heavy gas oils.
  • LPG liquefied petroleum gas
  • the cracking feed stream 14 may be preheated prior to being introduced into the reactor 12. In particular applications, the feed stream 14 may be heated to a temperature of from 25 °C to 500 °C to improve conversion efficiency or vaporize heavier liquid hydrocarbons either externally or within the reactor
  • the oxygen-gas feed 16 for combustion of a hydrogen-rich fuel gas feed 18 is also fed to the reactor 12 as a separate stream.
  • the oxygen-gas feed 16 may be a concentrated oxygen-gas feed, wherein a majority of the feed (i.e., >50 mol%) is composed of oxygen gas (O 2 ).
  • the oxygen-containing gas will be a high-purity oxygen-containing gas feed composed of O 2 in an amount of from 20 mol% to 100 mol% of the oxygen gas feed stream. This may be that provided from an air separation unit (not shown) used for separating oxygen gas from air or other oxygen-gas source. Air may also be used as the oxygen-containing gas. In cases where air is used as the oxygen-containing gas, or cases where there are large amounts of impurities (e.g., N 2 ) in the oxygen-containing gas feed, separation of such impurities from the product may be necessary downstream.
  • impurities e.g., N 2
  • a steam or water (H 2 O) feed is also feed to the reactor 12 as separate steam feed stream 20.
  • the cracking feed 14, fuel 18, and/or oxygen-gas feed 16 may also be premixed with steam in certain embodiments. In some instances, the separate steam feed stream 20 may be eliminated where sufficient steam is provided and mixed with the feeds 14 and/or 16.
  • Cracked reaction products 22 are removed from the reactor 12 where they may be cooled by quenching in a quenching unit 24, such as a water-droplet-spray quench vessel, or other suitable gas quench devices.
  • the cracked products 22 will typically be a mixture of hydrogen gas, steam, oxygenates, some heavies (>C4), some aromatics, and product olefins.
  • the quenched cracked reaction products 26 may be delivered to a separation unit 28, where the product gases are separated to form a product stream 30 containing product olefins, such as ethylene (C 2 H 4 ), propylene (C 3 H 6 ), and others, and a separated gas stream 32.
  • product gases such as ethylene (C 2 H 4 ), propylene (C 3 H 6 ), and others, and a separated gas stream 32.
  • the separated gas stream 32 is removed from the separator 28 and will typically contain hydrogen gas (H 2 ), with minor amounts of methane (CH 4 ), and carbon oxides of CO and CO 2 .
  • H 2 hydrogen gas
  • CH 4 methane
  • CO 2 can be separated before separating other gases so that recycled gas stream 32 may contain only H 2 , CH 4 , and CO.
  • the gas stream 32 may be recycled and fed as the hydrogen-rich fuel feed 18.
  • enough fuel gas e.g., H 2
  • H 2 is recycled during the cracking reaction so that no additional fuel is needed in addition to that supplied by the recycle stream 32.
  • additional fuel feed 34 of a hydrogen-rich or natural gas feed may be used for the fuel feed 18, such as an initial fuel feed during reactor startup, or that is combined with the recycle stream 32 to form the fuel feed 18 when an insufficient amount of hydrogen is available in the recycle stream 32 for combustion reaction heat.
  • the operational conditions of the reactor 12 may vary.
  • the oxygen feed 16 is typically used with excess hydrogen or fuel gas so that all the oxygen is consumed.
  • the amount of hydrogen will be 1 or 2 to 4 times the stoichiometric amount needed for combustion with oxygen.
  • hydrogen is sub-stoichiometric (below 1) to allow for additional exothermic reactions in the mixing zone.
  • the oxygen feed 16 may provide an oxygen equivalent-to-fuel mole ratio of from 0.125 to 0.50.
  • the ratio between the crack feed to hydrogen fuel will typically range from 1.0 to 15 based on mass depending on the hydrocarbon feed.
  • the residence time within the reactor 12 may range from 50 milliseconds or less, more particularly from 20 milliseconds or less.
  • recirculation zone temperature within the reactor will typically range from 1000 °C to 1300 °C.
  • the pressure at the reactor outlet may vary.
  • a suitable pressure at the reactor outlet may range from 0 kPa (g) to 10,000 kPa (g), more particularly from 0 kPa (g) to 1,000 kPa (g).
  • each unit could be composed of one or more units that may operate in conjunction with one another, such as parallel or sequentially, to carry out the various process steps described.
  • the reactor 12 constitutes an ANJEVOC-C reactor and includes a reactor vessel 36 having a reactor wall 38 that defines an interior reaction chamber 40.
  • the reactor wall 38 may have a cylindrical configuration with a constant diameter along all or a portion of its length, which may constitute a majority of its length. In most instances, the reactor 12 is oriented vertically so that the cylindrical reactor wall 38 is oriented in an upright orientation.
  • the reactor can have other orientations (e.g., horizontal, sloped, or downward), however, because the process is controlled by the centrifugal force, which exceeds the gravitational force by several orders of magnitude.
  • the reactor vessel 36 may be configured to provide a length to diameter ratio (L/D) of at least 2. In particular applications, the LID ratio may range from 2-10, more particularly from 2-5.
  • the reactor vessel 36 may be formed from steel.
  • a cooling jacket can be provided around the reactor vessel, wherein a second steel wall 42 is positioned around and spaced from the inner reactor wall 38 and a cooling fluid, such as water may be circulated through the jacket formed between the walls 38, 42.
  • the reactor wall 38 may be formed from one or more layers of refractory material that line the interior of an outer steel wall to reduce heat loss and sustain the high temperatures of the reactor 12. As will be described later on, because of the unique design and operation of the reactor 12, the reactor wall 38 is cooled internally by the high-velocity near-wall gas flow pushed by centrifugal forces against the reactor wall 38 so that in some applications no exterior cooling jacket is required.
  • Refractory materials typically cannot be used with conventional cracking reactors with pure oxygen due to the higher temperatures (e.g., from 2000 °C to 2800 °C) encountered.
  • An outlet 44 is provided at the upper or downstream end of the reactor vessel 36 for removing or discharging cracked products from the reaction chamber 40.
  • the outlet 44 is shown located at the upper end of the reactor vessel 36, in other embodiments it may be located at the lower end of the reactor vessel 36, so that the flow through the reactor is in the opposite direction (i.e., from top to bottom).
  • the outlet diameter can be same as the diameter of the reactor wall 38 or the outlet diameter may be reduced to accelerate the flow before quenching and collection downstream.
  • the reactor 12 includes a reactor inlet assembly 46 that is coupled or j oined to the lower or upstream end of the reactor wall 38 of the reactor vessel 36.
  • the inlet assembly 46 has a converging conduit 48 with a circumferential wall 50 that surrounds a central longitudinal axis 52 of the reactor. Where the reactor 12 is oriented vertically, the central axis 52 will also be oriented vertically as well and will be concentric with or parallel to a central vertical axis of the reactor vessel 36. In the embodiment shown, the axis 52 is concentric with and aligned with the central longitudinal axis of the reactor vessel 36.
  • the circumferential wall 50 extends from opposite upstream and downstream ends of the converging conduit 48.
  • the terms “upstream” and “downstream” or similar expressions with respect to describing various components of the reactor system 12 shall refer to the position of the component with respect to the direction of overall fluid flow through the reactor 12 along the central axis 52.
  • the circumferential wall 50 smoothly tapers in width or diameter from the downstream and upstream ends to an annular constricted neck portion 54 located between the downstream and upstream ends of the converging conduit 48.
  • the interior of the circumferential wall 50 may have a circular perpendicular transverse cross section (with respect to the axis 52) along its length.
  • the circumferential wall 50 defines an interior flow path of the inlet assembly 46 with the constricted neck portion 54 forming a converging-diverging streamlined nozzle of the inlet assembly 46.
  • the nozzle geometry of the neck portion 54 is configured based upon the theory relating to swirling conical jets of a viscous incompressible fluid.
  • the circumferential wall 50 of the converging conduit 48 from the downstream end where it joins reactor wall 38 to the annular constricted neck portion 54 may, in some embodiments, be configured as a smooth, continuous concave wall having an ellipsoidal cap or spherical cap shape or configuration.
  • the upstream portion of the reactor wall 38 of the reaction chamber 40 that joins the circumferential wall 50 of the converging conduit 48 may also be configured as a smooth, continuous concave wall that follow contour lines of an ellipsoidal cap or spherical cap shape or configuration.
  • the downstream end of the converging conduit 48 joins the reactor wall 38 around its perimeter so that the converging conduit 48 is in fluid communication with the reactor chamber 40 of the cracking reactor vessel 36.
  • the upstream end of the converging conduit 48 forms a reactor inlet 56 of the reactor vessel 36.
  • a reactor feed assembly 58 is provided with the reactor 12.
  • the reactor feed assembly 58 is in fluid communication with the reactor inlet 56 of the inlet assembly 46, with the central axis 52 passing through the reactor feed assembly 58.
  • the feed assembly 58 includes a downstream feed assembly wall 60 that extends circumferentially around and joins the upstream end of the reactor inlet 56.
  • the feed assembly wall 60 or circumferential portions thereof are oriented perpendicularly or substantially perpendicularly (i.e., ⁇ _ 5 degrees from perpendicular about its circumference as it extends radially from the central axis) to the central axis 52.
  • Axially spaced upstream from the downstream wall 60 along the central axis 52 is an upstream feed assembly wall 62.
  • the upstream wall 62 or circumferential portions thereof are oriented perpendicular to or substantially perpendicularly (i.e., ⁇ _ 5 degrees from perpendicular about its circumference as it extends radially from the central axis) to the central axis 52 and extends across the central axis 52.
  • An upstream gas partition wall 64 and a downstream gas partition wall 66 are axially spaced between the downstream and upstream feed assembly walls 60, 62 and are axially spaced from one another, with the upstream wall 64 being positioned upstream from the downstream partition wall 66.
  • the partition walls 64, 66 or circumferential portions thereof are also each oriented perpendicularly to or substantially perpendicularly (i.e., ⁇ _ 5 degrees from perpendicular about its circumference as it extends radially from the central axis) to the central axis 52.
  • the inner ends of the partition walls 64, 66 terminate at a position below the converging conduit 48 to define a central opening 68, 70, respectively, that surrounds the central axis 52 and is concentric with the converging conduit 48.
  • the central openings 68, 70 each have a circular configuration. Other shapes for the central openings 68, 70 (e.g., oval) may also be used provided such configuration facilitates the swirling of gases to provide the required flow patterns described herein. This shape may also correspond to the cross-sectional shape of the circumferential wall 50 of the converging conduit 48. In most applications, however, the central openings 68, 70 will be circular in shape.
  • the central openings 68, 70 may have a diameter or width that is the same or slightly different than the diameter or width of the constricted neck 54 of the converging conduit 48 at its narrowest point.
  • the upstream partition wall 64 defines an annular gas flow space 72 located between the upstream feed assembly wall 62 and the upstream side of the upstream partition wall 64.
  • the flow space 72 constitutes an upstream annular hydrocarbon cracking feed inlet flow space.
  • an annular gas flow space 74 is defined by the downstream side of the downstream partition wall 66 and the downstream feed assembly wall 60.
  • the flow space 74 constitutes an annular steam or water inlet flow space.
  • a further annular flow space 76 is defined between the upstream side of the downstream gas partition wall 66 and the downstream side of the upstream gas partition wall 64.
  • An intermediate partition wall 78 is axially spaced between the downstream gas partition wall 66 and the upstream gas partition wall 64 to define downstream and upstream intermediate annular gas inlet flow spaces 80, 82.
  • the intermediate partition wall 78 or circumferential portions thereof is also oriented perpendicularly to or substantially perpendicularly (i.e., ⁇ _ 5 degrees from perpendicular about its circumference as it extends radially from the central axis) to the central axis 52.
  • the intermediate partition wall constitutes a fuel gas partition wall that defines the flow spaces 80, 82, which constitute first and second annular fuel gas inlet flow spaces.
  • the inner end of the intermediate partition wall 78 terminates to define a central opening 84 that surrounds the central axis 52 of the converging conduit 48, and wherein the periphery of the central opening 84 of the fuel gas partition wall 78 is spaced radially outward a distance from the central openings 68, 70 of the upstream gas partition wall 64 and the downstream gas partition wall 66, as is shown.
  • the area spaced radially inward from the central opening 84 of the intermediate partition wall 78 between the upstream and downstream gas partition walls 64, 66 defines an annular combustion zone 86.
  • the size of the central opening 84 can vary to fit the radial extent of combustion zone 86.
  • This configuration provides flow passages through which hydrocarbon gas feed to be cracked, steam, oxygen gas, and hydrogen-rich fuel for providing combustion heat can each be separately introduced and passed through the flow spaces 72, 74, 80, 82, respectively, perpendicularly or substantially perpendicular to the central axis 52 of the converging conduit 48.
  • the lowermost or upstream flow space 72 will constitute a hydrocarbon cracking feed inlet flow space.
  • the steam feed may be introduced into the uppermost or upstream annular steam inlet flow space 74.
  • the hydrocarbon cracking feed may be introduced into the uppermost or downstream flow space 74 and the steam feed may be introduced into the lowermost or upstream flow space 72.
  • a fuel gas feed comprised of an hydrogen-rich gas feed may be introduced into one of the first and second adjacent annular fuel gas inlet flow spaces 80, 82, with an oxidizer or oxygen-containing gas feed being introduced into the other of the flow spaces 80, 82.
  • the downstream flow space 80 may be used for delivering the oxidizer or oxygen-containing gas and the upstream flow space 82 will be used for delivering the hydrogen-rich fuel gas. In other instances, these may be reversed or altered in other sequences.
  • the flow passages 72, 74, 80, 82 are configured so that the different feeds pass through flow spaces perpendicularly or substantially perpendicularly to the central axis 52 of the converging conduit 48 in an inwardly swirling fluid flow pattern within said flow spaces so that the feeds flow about the central axis 52 of the converging conduit 48.
  • the fuel gas and oxidizer feeds combust primarily in the small combustion zone 86 between the upstream and downstream partition walls 64, 66 within the central opening 84 of the fuel gas partition wall 78.
  • the walls 60, 62, 64, 66, and 78 forming the different flow spaces 72, 74, 80, 82 may be parallel to one another in many cases, but may be non-parallel to one another in certain cases.
  • the walls 60, 62, 64, 66, and 78 are axially spaced apart to provide the desired volume and flow characteristics for the gases flowing through them. This may be based upon the desired flow rates or linear velocities of each of the feed gases and their relative amounts. For instance, the relative volume of oxygen gas needed for the combustion is typically smaller than that of the hydrogen-rich fuel gas needed for the combustion. Therefore, the partition wall 78 may be spaced closer to the downstream partition wall 66 so that the flow space 82 for the hydrogen fuel is larger to accommodate the greater flow of fuel gas. The particular spacing may depend on fuel gas and oxidizer combination, the desired volume for combustion, and cracking feeds.
  • Annular gas manifolds 88, 90, 92, 94 may be provided around the outer periphery of the flow spaces 72, 74, 80, 82, respectively.
  • the gas manifold 88 is fluidly coupled to a cracking feed source, such as cracking feed 14 of FIG. 1 .
  • the manifold 90 is fluidly coupled to a steam source, such as the steam feed 20 of FIG. 1 .
  • the manifold 92 is fluidly coupled to an oxygen-containing-gas source, such as the oxygen gas feed 16 of FIG. 1 .
  • the manifold 92 is fluidly coupled to a hydrogen-rich or fuel feed source, such as the fuel feed 18 of FIG. 1 .
  • the manifolds 88, 90, 92, 94 are provided with the reactor feed assembly 58 to facilitate introduction of feed gases into the flow spaces 72, 74, 80, 82.
  • Gas inlets 96, 98, 100, 102 from the manifolds 88, 90, 92, 94, respectively, may be directed tangentially into the flow spaces 72, 74, 80, 82 so that the gases are not directed only radially toward the central axis 52 from the inlets 96, 98, 100, 102, but instead are directed mostly tangentially around the central axis 52 to provide an inwardly swirling flow pattern.
  • each flow space 72, 74, 80, 82 may have one or more tangential inlets, such as the inlets 96A and 96B, 98A and 98B, 100A and 100B, and 102A and 102B.
  • the walls 60, 62, 64, 66, and 78 forming the different flow spaces of the feed assembly 58 keep the gases introduced from the manifolds 88, 90, 92, 94 from flowing axially along the central axis 52 while they are contained within the flow spaces 72, 74, 80, 82.
  • the manifolds 88, 90, 92, 94 can be configured as standard manifolds (e.g., snail-like) as may be typically used in vortex devices.
  • one or more or all of the flow spaces 72, 74, 80, 82 may be provided with a plurality of circumferentially spaced guide vanes 104, 106, 108, 110 (e.g., 10 to 60 guide vanes).
  • Each guide vane 104, 106, 108, 110 may be a planar member that is oriented in a plane that is parallel to the central axis 52 and extends between the walls 60, 62, 64, 66, and 78.
  • the guide vanes 104, 106, 108, 110 may be circumferentially spaced an equal distance from one another.
  • the guide vanes 104, 106, 108, 110 may be fixed in place, with the upper and lower side edges of the guide vanes being joined along their lengths or a portion of their lengths to the walls 60, 62, 64, 66, and 78 so that there are no air gaps between the side edges of the vanes 104, 106, 108, 110 and the walls 60, 62, 64, 66, and 78.
  • the guide vanes are movable. In such cases, the upper and lower side edges of the vanes 104, 106, 108, 110 may be closely spaced from the walls 60, 62, 64, 66, and 78 to provide a small clearance to allow such movement but that minimizes air gaps where gases may pass through.
  • the vanes 104, 106, 108, 110 may be oriented so that the plane of the vane is in a non-parallel or slanted orientation relative to the central axis 52.
  • the side edges may be fixed to the walls 60, 62, 64, 66, and 78 or remain closely spaced from walls 60, 62, 64, 66, and 78 to minimize air gaps for gasses to pass through.
  • the guide vanes 104, 106, 108, 110 may be configured as airfoils, such as National Advisory Committee for Aeronautics (NACA) airfoil shapes, as described in E.N. Jacobs, K.E.
  • NACA National Advisory Committee for Aeronautics
  • the guide vanes may have curved surfaces, which may be oriented with the width being parallel or non-parallel to the axis 52, to provide desired flow characteristics, such as reduced drag and pressure drop.
  • desired flow characteristics such as reduced drag and pressure drop.
  • the guide vanes 104, 106, 108, 110 are provided adjacent to the outer perimeter of the flow spaces 72, 74, 80, 82 and are spaced in an annular or circular ring pattern near the manifold inlets 96, 98, 100, 102, respectively, although they may be provided in an annular pattern at other positions located radially inward or further within the interior of the flow spaces 72, 74, 80, 82, or one or more additional annular sets of guide vanes may be located radially inward from those located along the outer periphery to facilitate inwardly swirling fluid flow.
  • Feed gases from the manifolds 88, 90, 92, 94 are delivered nearly tangentially to the outer perimeter of the flow spaces 72, 74, 80, 82, where the guide vanes 104, 106, 108, 110 further facilitate directing the gas flow in an inwardly swirling or spiraling fluid flow pattern within the flow spaces 72, 74, 80, 82.
  • the guide vanes 104, 106, 108, 110 may impart the full tangential flow of the introduced gases in cases where the gas from inlets 96, 98, 100, 102 may be directed radially toward the central axis 52. In such cases the guide vanes 104, 106, 108, 110 prevent flow directly toward the central axis 52 and direct the flowing gases tangentially to provide the inwardly swirling or spiraling fluid flow pattern.
  • the guide vanes 104, 106, 108, 110 of each flow space 72, 74, 80, 82 may be mounted on actuators (not shown) so that they can be selectively movable to various positions to provide a selected inwardly spiraling flow pattern.
  • the guide vanes 104, 106, 108, 110 may be pivotal about an axis that is parallel to the central axis 52 so that the vanes 104, 106, 108, 110 may be moved to various positions.
  • the orientation of the vanes 104, 106, 108, 110, as well as the orientation of the tangential inlets 96, 98, 100, 102 may be seen in FIG. 4 .
  • the line 112 represents the angle of orientation of the vanes 104, 106, 108, 110 and/or inlets 96, 98, 100, 102 with respect to the radial line 114 extending radially from the central axis 52.
  • Angle A is the angle between the tangential line 112 and the radial line 114.
  • the line 112 may correspond to or represent a chord line passing through the leading edge and trailing edge of the vane or airfoil.
  • the angle A may range from 50° to 90°, more typically from 60° to 85°.
  • the vanes 104, 106, 108, 110 may be permanently oriented at an angle A within this range or may be movable to various angular orientations within this range.
  • each of the vanes 104, 106, 108, 110 within the annular pattern will be set at the same angle A and when actuated will move in unison or close to unison to the same angle A to provide the desired swirling fluid flow characteristics.
  • the angle(s) of orientation A of the vanes 104, 106, 108, 110 and/or inlets 96, 98, 100, 102 of the different flow passages may be the same or different than the angle(s) of orientation of the vanes or inlets of the others.
  • the tangential gas inlets 96, 98, 100, 102 and/or the guide vanes 104, 106, 108, 110 will be oriented to provide swirling or spiraling fluid jet flow that is in the same rotational direction about the axis 52, i.e., clockwise or counter-clockwise.
  • gases within each of the flow spaces will flow clockwise or counterclockwise about the axis 52.
  • the area extending from the central openings 68, 70 of the partition walls 62, 70, respectively, to the reactor inlet 56 define a central mixing chamber 116. It is here that heated combustion gases from the flow space 76, hydrocarbon cracking feed from the upstream hydrocarbon feed inlet flow space 72, and steam from flow space 74 are discharged into the central chamber 116 so that hydrocarbon cracking feed, steam and heated combustion gases are mixed together and form a swirling gas mixture within the chamber 116. This swirling gas mixture then passes through the converging conduit 48 and into the reaction chamber 40 of the reactor vessel 36.
  • the oxygen-containing gas and hydrogen-rich fuel gas are introduced separately from one another into the flow spaces 80, 82, respectively, and not as mixture, this eliminates safety issues that would otherwise occur if these gases were premixed prior to their introduction into the feed assembly 58. Furthermore, the combustion reaction takes place very rapidly wherein most of the combustion occurs within a very small space within the combustion zone 86 where the two streams of oxygen-containing gas and hydrogen-rich fuel gas from the flow spaces 80, 82 are mixed immediately adjacent to the central opening 84 and prior to entering the chamber 116.
  • the combustible mixture can be ignited through spark or chemicals or pilot flame through bottom surface or side surfaces of the reactor as the suction from the strong swirling flow (that mimics a tornado) will transport the hot gases from the ignition device to the combustion zone 86 to initiate the ignition.
  • a cracking feed is introduced from manifold 88 to tangential inlets 96A, 96B into flow space 72.
  • the cracking feed may be ethane, LPG, butane, naphtha, natural gas, light gas oils, heavy gas oils, or their combinations. While these cracking feed materials are typically introduced as gases, in some instances they may be introduced as liquids. Once introduced as liquids they are rapidly vaporized within the reactor. This may be beneficial in that light and heavy gas oils, for example, are typically vaporized outside the reactor in conventional cracking systems. Such exterior vaporization creates coking issues, however. By injecting them directly into the reactor in liquid form, these issues are avoided.
  • the cracking feed will typically be denser than the combustion products. This is a result of both the high molecular weight of the cracking feed and its density at the selected temperature of the cracking feed.
  • the denser gas/liquids move outward while the lighter combustion products move inward due to very high centrifugal acceleration (100,000 - 1M g forces).
  • the denser hydrocarbons rapidly mix into the peripheral combustion products at very high temperature due to high swirl.
  • a hydrogen-containing fuel gas is introduced from manifold 94 to tangential inlets 102A, 102B into flow space 82.
  • the hydrogen-containing fuel gas may be hydrogen gas (H 2 ) and/or methane (CH 4 ).
  • the methane may be present in the fuel gas in an amount of from 20 mol%, 15 mol%, 10 mol%, 5 mol% or less. Greater amounts of methane may impact the desired selectivity. In other embodiments, however, greater amounts of methane may be used, including 100% methane for the fuel gas. Natural gas may also be used as the fuel gas.
  • the hydrogen-containing fuel gas may be a hydrogen-gas-rich stream composed primarily of hydrogen gas, which may be a recycled stream such as the recycle stream 32 ( FIG. 1 ) or additional hydrogen gas, such as the stream 34.
  • the hydrogen-gas-rich stream may contain other components such as methane, CO, steam, inert gases, and CO 2 .
  • Other hydrocarbons can also be used as the fuel gas in certain embodiments and applications. Additionally, small amounts of N 2 can also be present.
  • Sulfur can also be present in the fuel gas or other feed streams. If sulfur is present, additional separation upstream or downstream may be required.
  • the reactor and process are sufficiently robust to accommodate the presence of sulfur, particularly since no catalyst is used.
  • the ratio between the crack feed to hydrogen-containing fuel will typically range from 1 to 15, more particularly from 1 to 10, based on mass.
  • An oxidizer or oxygen-containing gas which may be a concentrated or pure oxygen gas, such as from an air separation unit (not shown), is introduced as the oxidizer feed through manifold 92 through inlets 100A, 100B into the flow space 80. Having the oxygen-containing gas introduced through flow space 80 spaces it further from the cracking gas introduced through flow space 72 to eliminate or minimize any combustion of the introduced cracking gas.
  • the mole ratio of H 2 /O 2 may range from 2 to 9 , more particularly from 2 to 5, and still more particularly from 2 to 4.
  • the oxygen feed may provide an oxygen equivalent-to-fuel mole ratio of from 0.2 to 1.0.
  • An excess of hydrogen also helps to scavenge free radicals (e.g., O, OOH, OH) formed that would otherwise react with the cracking feed.
  • a mole ratio of H 2 /O 2 may be less than 2 to compensate for other fuel gases or to have excess O 2 in the mixing region to release heat to counter endothermic cracking reactions.
  • Steam or water is introduced through manifold 90 and through inlets 98A, 98B into the flow space 74. Steam is introduced upstream of the other feeds and is used to cool the walls of the converging conduit 48 and reactor 12. The introduced steam also facilitates reducing the reaction temperatures within the reactor 12. Steam may also be pre-mixed with the various feeds, such as with the cracking gas feed, fuel gas, and/or oxygen-containing feed. Steam may be used in a mass ratio of steam-to-fuel of from greater than 0 to 10.0, more particularly from 0 to 2.0, in certain applications.
  • FIG. 5 shows a schematic diagram of the reactor 12 with the individual flows of the different feeds. These individual flows are schematically represented by dashed lines.
  • all of the oxygen gas and at least a portion of the hydrogen-containing fuel gas are combusted to form heated combustion products that are almost entirely mixed with the other feeds prior to exiting the converging conduit 48 and entering the reaction chamber 40.
  • the gases flowing into the reaction chamber 40 constitutes a gas mixture.
  • the denser gases e.g., cracking feed
  • the hotter combustion products tend to flow through the center of the reactor.
  • the device geometry and the swirling gas-mixture from chamber 116 results in a back flow of the gas mixture as represented by dashed lines 118.
  • This mixture flows upstream and radially inward from the thin, outer annular mixed gas flow layers 120, 122, circulating within the reaction chamber 40 to form recirculation zone 124.
  • Internal cooling of the walls occurs due to the high swirling steam delivered through flow space 74 in FIG. 2 . Additional cooling (if necessary) occurs by a water jacket located between walls 38 and 42 in FIG. 2 .
  • the gas feed streams may be introduced to provide different flow velocities to provide the Kelvin-Helmholtz instability for enhanced mixing.
  • the flow velocities may range from 10 m/s to 500 m/s, more particularly from 100 m/s to 400 m/s.
  • the reactor may be operated at from 0 kPa (g) or 100 kPa (g) to 1,000 kPa (g), 2,000 kPa (g) or as much as 10,000 kPa (g), with a gas residence time within the reactor of from 50 milliseconds or less, more particularly from 20 milliseconds or less, and still more particularly from 10 microseconds to 20 milliseconds.
  • the residence time may range from 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, or 10 milliseconds or less, with 10 microseconds being the approximate lowest residence time.
  • the reaction temperature within the reactor and recirculation zone 124 may range from 900 °C to 1300 °C. In particular embodiments, the temperature within the reactor and recirculation zone 124 may range from 1000 °C to 1300 °C, more particularly from 1200 °C to 1250 °C. In some embodiments, the reactor temperature is higher than what is achieved in conventional cracking reactors, such as tube furnace reactors, which typically operate at 800 °C to 900 °C. As discussed earlier, this is due to the temperature limitations of the metallic materials used for such conventional reactors. In the present case, the swirling gas mixture facilitates keeping the walls of the reactor much cooler than in such conventional reactors. The use of such higher temperatures also allows a shorter residence or contact times shorter contact times resulting in better selectivity and conversion without formation of unwanted products. Operating temperatures for the reactor may be selected to avoid excess production of such unwanted compounds, such as acetylene.
  • the gases are introduced and flow through the flow spaces 72, 74, 80, 82 so that the axial velocity (i.e., relative to the axis 52) is zero prior to being discharged into the mixing chamber 116.
  • the tangential inlets 96, 98, 100, 102 and/or the orientation of the guide vanes 104, 106, 108, 110 may be set for each flow space 72, 74, 80, 82 so that a selected azimuthal-to-radial velocity for each of the feed streams that flow through the flow spaces 72, 74, 80, 82 is achieved.
  • azimuthal-to-radial velocity in particular embodiments, this may range from 0 to 30 or more, more particularly from 0, 1, or 2 to 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30.
  • the azimuthal-to-radial velocity may range from 0 to 5, more particularly from 2 to 4.
  • the particular azimuthal-to-radial ratio may vary depending upon the particular reactor configuration and composition of the various streams, however. This is more intimately related to the mixing times and reaction times depending on the flow rates, composition of the fuel and feedstocks used for cracking.
  • additional cracking feed gas can be introduced as a secondary feed stream at an intermediate position along the length of reactor vessel 36, such as at inlet 126 ( FIG. 2 ).
  • inlet 126 FIG. 2
  • One or more such inlets 124 may be provided at various locations and in the reactor vessel 36, which may be circumferentially and longitudinally spaced apart.
  • the inlets 126 may be oriented or configured so that gases are introduced tangentially, as well, to facilitate swirling fluid flow, similar to that delivered from the inlets of the feed assembly 58.
  • Feed assemblies provided on the reactor vessel 36 similar to the feed assembly 58 may be used for the introduction of such cracking feed gas so that the cracking feed is introduced as a swirling fluid flow.
  • a plurality of reactor inlet assemblies and corresponding feed assemblies can be provided in a single reactor while maintaining the high performance.
  • reactor 128 is similar to reactor 12, previously described, with similar components labeled with the same referenced numerals.
  • the reactor 128 includes a reactor feed assembly 130, which is similar to the feed assembly 58 previously described with some differences with respect to the partition walls located between the downstream feed assembly wall 60 and the upstream feed assembly wall 62.
  • the feed assembly 130 has an upstream gas partition wall 132 and a downstream gas partition wall 134 that are axially spaced between the downstream and upstream feed assembly walls 60, 62.
  • An intermediate partition wall 136 is axially spaced between the upstream gas partition wall 132 and the downstream gas partition wall 134, with the partition walls 132, 134, 136 being axially spaced from one another.
  • the partition walls 132, 134, 136 or circumferential portions thereof are also each oriented perpendicularly to or substantially perpendicularly (i.e., ⁇ _ 5 degrees from perpendicular about its circumference as it extends radially from the central axis) to the central axis 52.
  • Each of the partition walls 132, 134, 136 terminates at their inner ends at a position below or upstream of the converging conduit 48 to define central openings 138, 140, 142, respectively, that surrounds the central axis 52 and are concentric with the converging conduit 48.
  • the central openings 138, 140, 142 each have a circular configuration. Other shapes for the central openings 138, 140, 142 (e.g., oval) may also be used provided such configuration facilitates the swirling of gases to provide the required flow patterns described herein. This shape may also correspond to the cross-sectional shape of the circumferential wall 50 of the converging conduit 48. In most applications, however, the central openings 138, 140, 142 will be circular in shape.
  • the central openings 138, 140, 142 may have a diameter or width that is the same or slightly different than the diameter or width of the constricted neck 54 of the converging conduit 48 at its narrowest point.
  • the central opening 138 of the upstream partition wall 132 may have a periphery that is spaced radially outward a distance from the central opening 142 of the intermediate partition wall 136, as is shown.
  • the area spaced radially inward from the central opening 142 of the intermediate partition wall 136 between the upstream feed assembly wall 62 and the intermediate partition wall 136 defines an annular combustion zone 144.
  • the size of the central opening 138 can vary to fit the radial extent of combustion zone 144.
  • the upstream partition wall 132 is axially spaced between the upstream feed assembly wall 62 and the intermediate partition wall 136 to define flow spaces 146, 148 which constitute first and second annular fuel gas inlet flow spaces.
  • the flow space 146 constitutes an upstream annular fuel gas feed inlet flow space
  • the flow space 148 constitutes a downstream annular fuel gas feed inlet flow space.
  • the fuel gas feed may be comprised of an oxygen-containing fuel gas feed and a hydrogen-rich fuel gas feed, as described previously, that are introduced into the first and second annular fuel gas inlet flow spaces 146, 148, as with reactor 12.
  • the flow space used for the oxygen-containing will be spaced furthest from the hydrocarbon cracking feed flow to prevent or minimize any combustion of the cracking feed.
  • the oxygen-containing gas would be introduced into flow space 146.
  • Either of the oxygen-containing or hydrogen-rich fuel gases introduced into flow spaces 146, 148, or both, may be introduced with a steam cofeed.
  • An annular gas flow space 150 is defined by the downstream side of the downstream partition wall 134 and the downstream feed assembly wall 60.
  • the flow space 150 may constitute an annular hydrocarbon cracking feed inlet flow space or alternatively a steam feed inlet flow space.
  • a further annular flow space 152 is also defined between the upstream side of the downstream gas partition wall 134 and the downstream side of the intermediate partition wall 136.
  • the flow space 152 may constitute an annular steam or water inlet flow space or alternatively an annular hydrocarbon cracking feed inlet flow space.
  • a separate steam feed to the feed assembly 130 may be eliminated.
  • one of the flow spaces 150, 152 may be eliminated by the removal of either the partition walls 134, 136 and the intervening flow space.
  • the flow passages 146, 148, 150, 152 are configured so that the different feeds pass through flow spaces perpendicularly or substantially perpendicularly to the central axis 52 of the converging conduit 48 in an inwardly swirling fluid flow pattern within said flow spaces so that the feeds flow about the central axis 52 of the converging conduit 48.
  • Guide vanes 104, 106, 108, 110 may also be used to facilitate swirling fluid flow.
  • the fuel gas feed from flow combusts primarily in the small combustion zone 144 between the inner end of partition wall 136 and upstream feed assembly wall 62 within the central opening 138 of the upstream partition wall 132.
  • the oxidizing gas nears complete combustion in the combustion zone 144, located below the cracking feed introduced into one of the flow passages 150, 152. Therefore, the cracking gas meets only combustion products above the zone 144. Additionally, the cold flow of the incoming cracking gas in the flow passage 150 or 152 moderates the temperature of the circumferential wall 50 of conduit 48 as it flows through the reactor inlet 46 and also protects the reactor walls 38 from overheating.
  • the reactor 128 also differs from the reactor 12 in that the wall 42 ( FIG. 2 ) for the cooling jacket is eliminated.
  • one or more cooling gas feed assemblies 154, 156 are provided for introducing or injecting cooling gases into the reactor 128.
  • the cooling gases may be a neutral or inert gas, such as steam, which may be at a temperature sufficient to provide the desired cooling effect. This may include steam at a temperature of from 100 °C to 250 °C (e.g., 150 °C).
  • the cooling gas can also be hydrocarbon cracking feed at a relatively lower temperature, for example from 25 °C to 500 °C.
  • the cooling gas feed assemblies 154, 156 may be configured similarly to the feed assemblies 58, 130 of the reactors 12 and 128 to provide a swirling flow of cooling gases as they are introduced into the reactor 128.
  • Each cooling gas feed assembly 154, 156 is constructed from a pair of axially spaced apart cooling gas feed assembly walls 158, 160 oriented perpendicular or substantially perpendicular (i.e., ⁇ 5 degrees from perpendicular about its circumference as it extends radially from the central axis) to the central axis 52.
  • An annular cooling gas inlet flow space 162 is defined between the cooling gas feed assembly walls 158, 160 of each cooling gas feed assembly 154, 156.
  • the cooling gas feed assembly 154 constitutes a downstream cooling assembly with the inlet flow space 162 communicating with a circumferential opening or inlet 164 of the reactor wall 38 and the reaction chamber 40.
  • the position of the feed assembly 154 and inlet 164 may be located at a position along the length of the reactor wall 38 or cylindrical portions of the reactor wall 38 above the contoured, concave or tapered portion 166 and above the reactor inlet assembly 46 and converging conduit 48.
  • the cooling gas feed assembly 156 constitutes an upstream cooling assembly with the inlet flow space 162 communicating with a circumferential opening or inlet 168 of the reactor wall 38 or circumferential wall 50 along the contoured, concave or tapered portion 166 where the reactor wall 38 and circumferential wall 50 of the converging conduit 48 meet.
  • Each of the annular flow spaces 162 of the cooling gas feed assemblies 154, 156 may also be provided with a plurality of circumferentially spaced guide vanes 170 to facilitate swirling fluid flow within the cooling gas inlet flow spaces 162 of the feed assemblies 154, 156.
  • the guide vanes 170 may be constructed and operate similarly to the guide vanes 104, 106, 108, 110, previously described.
  • An annular cooling gas manifold 172 may be provided around the outer periphery of the flow spaces 162 of each of the feed assemblies 154, 156.
  • the gas manifold 172 is fluidly coupled to a cooling gas feed source, such as steam.
  • Cooling gas inlets 174 of the manifold 172 may be directed tangentially into the flow space 162 so that the cooling gases are not directed radially toward the central axis 52, but instead are directed mostly tangentially around the central axis 52 to provide an inwardly swirling flow pattern.
  • the walls 158, 160 forming the flow spaces 162 of the cooling gas feed assemblies 154, 156 keep the cooling gases introduced from the manifold 172 from flowing axially along the central axis 52 while they are contained within the flow spaces 162.
  • the manifolds 172 can be configured as standard manifolds (e.g., snail-like) as may be typically used in vortex devices.
  • the cooling effect allows the elimination of a cooling jacket and/or the use of refractory materials for the reactor 128.
  • cooling gas feed assemblies such as the feed assemblies 154, 156, may be provided as necessary along the length of the reactor 128 to facilitate sufficient cooling. Likewise, either one of the feed assemblies 154, 156 may be eliminated in certain embodiments.
  • a vane 176 that may be used for any one or all of the feed assemblies 58, 136, 154, 156.
  • the vane 176 is non-planar and is configured as an airfoil.
  • the vane 176 is configured to reduce drag and includes a leading end 178 and trailing end 180.
  • FIG. 8 shows a top plan view of the airfoil vane 176.
  • a chord or line 182 passing through the leading edge and trailing edge of the vane 176 may correspond to the line 112 of FIG. 4 .
  • the leading end 178 and trailing end 180 are joined by opposite sidewalls 184, 186 that converge at the trailing end 180.
  • the transverse dimensions of the vane 176 may be uniform along the height of the vane. In other embodiments, however, the transverse dimensions may vary along the height of the vane.
  • the curved sidewalls of the airfoil 176 may be represented by three arcs 188 190, and 192, which are shown exploded away from one another.
  • the arc 188 represents the leading end or leading end wall or cap of the vane 176.
  • the arc 190 constitutes a left arc representing the left sidewall 184 that joins the leading arc 184 at one end and terminates at the other end at the trailing end 180 of the airfoil 176.
  • the arc 192 constitutes a right arc representing the right sidewall 186 that joins the leading arc 184 at one end and terminates at the other end at the trailing end 180 of the airfoil 176.
  • FIG. 10 a schematic showing a pair of airfoil vanes 176A and 176B as they would be arranged within any one of the flow spaces of the gas inlet feed assemblies as has been previously described.
  • the trailing ends 180 are arranged around the perimeter of a circle 194 having a radius R, which defines the inner boundary of the gas vanes 176.
  • Points on the vanes 176A, 176B can be determined by the polar coordinates r and ⁇ .
  • k 1 can equal 0.85.
  • the right arc 192 is essentially the left arc 190 compressed to the y axis.
  • k 2 can equal 0.75.
  • each point for the left vane 176A i.e., x 1 , y 1
  • the procedure of calculating the right vane 176B can be repeated until all guide vanes are represented.
  • the control parameters R, N, k 1 , and k 2 can be modified for specific applications.
  • FIG. 11 shows another embodiment of a reactor 198 is shown.
  • the reactor 198 is similar to the reactors 12 and 128, previously described, with similar components labeled with the same referenced numerals.
  • the reactor 198 includes a reactor feed assembly 200, which is similar to the feed assemblies 58, 130 previously described with some differences.
  • the feed assembly 200 has an upstream gas partition wall 202 and a downstream gas partition wall 204 that are axially spaced between the downstream and upstream feed assembly walls 60, 62.
  • An upstream partition wall 202 is axially spaced between the upstream gas feed assembly wall 62 and the downstream gas partition wall 204, with the partition walls 202 and 204 being axially spaced from one another.
  • the partition walls 202, 204 or circumferential portions thereof are also each oriented perpendicularly to or substantially perpendicularly (i.e., ⁇ 5 degrees from perpendicular about its circumference as it extends radially from the central axis) to the central axis 52.
  • the downstream gas partition wall 204 differs from those previously described in that extending from the downstream partition wall 204 is a curved annular extended wall portion 206 that curves upward or downstream and is spaced from and follows the contours of the circumferential wall 50 of the converging conduit 48 of the reactor inlet assembly 46 and terminates at a position downstream of the annular constricted neck portion 54.
  • the partition wall 204 with the extended curved portion 206 defines a downstream inlet flow space 208 located in the annular space between the downstream feed assembly wall 60 and circumferential wall 50 of the reactor inlet assembly 46 and the partition wall 204 with the extended portion 206.
  • a curved portion 210 of the downstream inlet flow space 208 discharges at a central annular opening 212 that surrounds the central axis 52 into the reactor chamber 40 downstream from the constricted neck portion 54.
  • the upstream partition wall 202 terminates at its inward end at a position upstream from the converging conduit 48 and has a central opening 214 that surrounds the central axis 52 and is concentric with the converging conduit 48.
  • the central opening 214 has a circular configuration. Other shapes for the central opening 214 (e.g., oval) may also be used provided such configuration facilitates the swirling of gases to provide the required flow patterns described herein. This shape may also correspond to the cross-sectional shape of the circumferential wall 50 of the converging conduit 48.
  • the upstream partition wall 202 is axially spaced between the upstream feed assembly wall 62 and the downstream partition wall 204 to define flow spaces 216, 218 which constitute first and second annular fuel gas inlet flow spaces.
  • the flow space 216 constitutes an upstream annular fuel gas feed inlet flow space and the flow space 218 constitutes a downstream annular fuel gas feed inlet flow space.
  • the fuel gas feed may be comprised of an oxygen-containing fuel gas feed and a hydrogen-rich fuel gas feed, as have been described previously, that are introduced into the first and second annular fuel gas inlet flow spaces 216, 218. Either of the oxygen-containing or hydrogen-rich fuel gases introduced into flow spaces 216, 218, or both, may be introduced with a steam cofeed.
  • the flow space 208 may constitute an annular hydrocarbon cracking feed inlet flow space.
  • the flow passages 208, 216, 218 are configured so that the different feeds initially pass through flow spaces perpendicularly to the central axis 52 of the converging conduit 48 in an inwardly swirling fluid flow pattern within said flow spaces so that the feeds flow about the central axis 52 of the converging conduit 48.
  • Guide vanes 220, 223, 224 may be used to facilitate such swirling flow.
  • the cracking gas flows spirally upward through the curved portion 210 of the flow space 208 and is discharged through opening 212 into the reaction chamber.
  • the fuel gas feed from flow spaces 216, 218 combusts in the central chamber 116. Because the downstream partition wall 204 has an extended portion 206 that extends past the constricted neck portion 54 and separates the combusting fuel gases within the central chamber 116 where they are fully combusted or the oxygen-containing gas is fully consumed there is no danger of the introduced cracking gas being combusted.
  • the introduced cracking gas also facilitates cooling of the reactor walls.
  • the reactor designs described herein feature high conversion of the cracking feed and higher selectivity for olefins than other conventional cracking methods and at much higher pressures than typically used.
  • the reactors are relatively simple in configuration, which can significantly reduce the capital and operating costs.
  • the high-swirling gas mixture provides stable and compact combustion using non-premixed fuel gases (i.e., H 2 + O 2 ) that are combusted within a small combustion zone of the feed assembly.
  • the reactor walls are cooled by the swirling steam flow (or cooler feed) against the wall allowing for higher temperatures in the reactor, requiring shorter residence times, so that more desirable products (e.g., ethylene) are produced. Maintaining lower reactor wall temperatures also allows refractory materials to be used in place of metal materials and thus minimizing heat loss.
  • the feeds used were 72 kg/h ethane, 38 kg/h oxygen blending with 38 kg/h steam, 12 kg/h hydrogen, and another 18 kg/h steam stream near the wall of the reactor for wall protection. Based upon prior experience with similar reactors, one can scale this reactor to use 3600 kg/h ethane, 1800 kg/h oxygen blending with 1800 kg/h steam, 612 kg/h hydrogen, and another 900 kg/h steam stream near the wall of the reactor for wall protection.
  • FIGS. 12 and 13 show the cracking reactor geometry and axial velocity and swirl velocity distribution in a lab scale unit model.
  • the darker areas of FIG. 6 indicate a high axial velocity while the lighter areas indicate a low axial or negative (reverse flow) velocity relative to the longitudinal axis. Together with the axial velocity contour, arrows are presented on the same figure indicating flow directions.
  • the axial velocity was close to zero for each of the feeds, the radial and the azimuthal velocity were uniform, and the azimuthal-to-radial velocity ratio was 10 for all the inlet streams.
  • This highly swirling flow forms a recirculation region near the axis of the reactor as described above with respect to recirculation zone 124 of FIG. 5 . This can be seen by the lightest regions (reverse flow region in reaction chamber near the axis in FIG. 12 ). The highest axial flow regions were the darker areas along the converging conduit and along the reactor walls.
  • FIG. 13 shows the swirl velocity, with the darker regions representing higher swirl velocity and the lighter regions representing lower swirl velocity.
  • the swirl velocity is greatest along the outer edges of the mixing chamber of the feed assembly, with the greatest swirl velocity being along the constricted neck portion of the converging conduit.
  • the swirl velocity is also high along the sidewalls of the reactor where it joins the converging conduit.
  • FIG. 14 shows the stream function.
  • the through-flow goes near the reactor wall in the nozzle and the adjacent half of the cylindrical parts. There the reversed flow near the axis and the recirculation of mixed gases occurs between the axis and the wall.
  • the curves separating gray scales are streamlines.
  • FIG. 15 shows the mass fraction distribution of the ethane (C 2 H 6 ) cracking feed within the reactor system.
  • FIG. 16 shows the temperature profile of the reactor system. As shown, the combustion occurs within the combustion zone, corresponding to combustion zone 86 of the feed assembly 58 of FIG. 2 , with the higher temperatures from the combustion gases being located along the converging neck portion. Additionally, the steam feed provides a thin cooler layer immediately adjacent to the constricted neck portion. The temperature within the reactor itself is uniformly maintained at approximately 1200 °C.
  • FIGS. 17 , 18 , and 19 show the mass fraction distribution of the hydrogen gas, oxygen gas, and steam, respectively, within the reactor system.
  • FIG. 17 almost all of the feed hydrogen is burned in the combustion zone. Hydrogen produced by cracking is uniformly distributed in the cylindrical part of the reactor.
  • FIG. 18 all of the oxygen gas is immediately consumed within the combustion zone of the feed assembly, corresponding to combustion zone 86 of the feed assembly 58 of FIG. 2 .
  • FIG. 19 all the feed steam introduced through the steam inlet flow space protects the nozzle wall from overheating. All these components are uniformly distributed in the cylindrical part.
  • FIG. 20 shows the mass fraction distribution of atomic oxygen (O), which is produced and consumed within the combustion zone and nearly absent with the reactor system.
  • FIGS. 21 , 22 , and 23 show the mass fraction distribution of the cracked products of ethylene, acetylene, and propylene, respectively, formed within the reactor system.
  • FIG. 21 shows that C 2 H 4 is mostly produced in the nozzle and near the reactor wall.
  • FIG. 22 shows that C 2 H 2 is mostly produced in the nozzle.
  • FIG. 23 shows that the cracking finishes around two diameters axial distance downstream of the nozzle neck.
  • FIG. 24 shows the mass fraction distribution of the CO within the reactor system. The CO is produced near the nozzle neck because only 94% oxygen is burned within the combustion zone. The remaining 6% of oxygen reacts with the hydrocarbons.
  • a reactor network model was used with a detailed mechanism in order to examine the chemical kinetics limit and the maximum performance metrics of this novel design on varying feedstock.
  • One simulation (Case 1) was conducted with H 2 as fuel and C 2 H 6 as the cracking hydrocarbon similar to the CFD simulation in EXAMPLE 1.
  • a second simulation (Case 2) was conducted with H 2 as fuel and Naphtha (NP) as the cracking hydrocarbon.
  • a third simulation (Case 3) was also conducted using CH 4 as the fuel gas for naphtha cracking. The results were compared to a conventional ethane cracker and a conventional naphtha.

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Claims (15)

  1. Un système de réacteur (12, 128, 198) pour la conversion d'hydrocarbures comprenant :
    une cuve de réacteur (36) comportant une paroi de réacteur (38) qui définit une chambre de réaction (40) ;
    un ensemble d'entrée de réacteur (46) couplé ou joint à une extrémité inférieure ou supérieure de la paroi du réacteur (38), l'ensemble d'entrée de réacteur (46) ayant un conduit convergent (48) avec une paroi circonférentielle (50) qui entoure un axe central (52) et s'étend à partir des extrémités opposées en amont et en aval du conduit convergent (48), la paroi circonférentielle (50) s'amincissant en largeur à partir des extrémités aval et amont jusqu'à une portion de col rétréci annulaire (54) située entre les extrémités aval et amont du conduit convergent (48), l'extrémité aval du conduit convergent (48) étant en communication fluidique avec la chambre de réaction (40) du réacteur (12, 128, 198), l'extrémité amont du conduit convergent (48) formant une entrée de l'ensemble d'entrée du réacteur (46) ;
    un ensemble d'alimentation (58, 130, 200) en communication fluidique avec l'entrée (56) de l'ensemble d'entrée du réacteur (46), l'axe central (52) traversant l'ensemble d'alimentation (58, 130, 200), l'ensemble d'alimentation (58, 130, 200) comprenant :
    une paroi d'ensemble d'alimentation en aval (60) qui s'étend circonférentiellement autour de l'extrémité amont de l'ensemble d'entrée du réacteur (46) et la rejoint, la paroi d'ensemble d'alimentation en aval (60) étant orientée perpendiculairement ou sensiblement perpendiculairement à l'axe central (52) ;
    une paroi d'ensemble d'alimentation en amont (62) qui est axialement espacée en amont de la paroi d'ensemble d'alimentation en aval (60) le long de l'axe central (52) et qui s'étend perpendiculairement ou sensiblement perpendiculairement à travers l'axe central (52) ;
    une paroi de séparation des gaz en amont (64, 132, 202) perpendiculaire ou sensiblement perpendiculaire à l'axe central (52) et une paroi de séparation des gaz en aval (66, 134, 204) perpendiculaire ou sensiblement perpendiculaire à l'axe central (52), qui sont chacune espacées axialement entre les parois d'ensemble d'alimentation en aval et en amont (60, 62) et sont axialement espacées l'une de l'autre, la paroi de séparation des gaz en amont (64, 132, 202) et la paroi de séparation des gaz en aval (66, 134, 204) étant orientées perpendiculairement ou sensiblement perpendiculairement à l'axe central (52), au moins l'une pami la paroi de séparation des gaz en amont (64, 132, 202) et la paroi de séparation des gaz en aval (66, 134, 204) se termine à une position en amont du conduit convergent (48) pour définir une ouverture centrale (68, 70, 84, 138, 140, 142, 214) qui entoure l'axe central (52) du conduit convergent (48), un espace d'écoulement d'entrée annulaire en amont (72) étant défini entre la paroi d'ensemble d'alimentation en amont (62) et la paroi de séparation des gaz en amont (64, 132, 202), un espace annulaire d'écoulement d'entrée en aval (74) étant défini entre la paroi d'ensemble d'alimentation en aval (60) et la paroi de séparation des gaz en aval (66, 134, 204), et un espace d'écoulement d'entrée intermédiaire (76) défini entre la paroi de séparation des gaz en amont (64) et la paroi de séparation des gaz en aval (66) ; dans lequel ;
    lesdits espaces d'écoulement d'entrée annulaires (72, 74, 76) amènent les flux introduits à s'écouler perpendiculairement ou sensiblement perpendiculairement vers l'axe central (52) du conduit convergent (48), chaque espace d'écoulement d'entrée de conduit annulaire (72, 74, 76, 80, 82, 146, 148, 216, 218) ayant une entrée (96, 98) orientée tangentiellement dans l'espace d'écoulement et/ou des aubes directrices espacées les unes des autres (104, 106, 108, 110) orientées de manière à fournir un modèle d'écoulement de fluide tourbillonnant vers l'intérieur à l'intérieur desdits espaces d'écoulement autour de l'axe central (52) du conduit convergent (48) ; et dans lequel
    la zone s'étendant depuis l'ouverture centrale (68, 70, 84, 138, 140, 142, 214) d'au moins une des parois de séparation en amont et en aval (64, 132, 202, 66, 134, 204) jusqu'à l'entrée (56) de l'ensemble d'entrée du réacteur (46) définit une chambre centrale (116) de l'ensemble d'alimentation (58), les gaz de combustion chauds provenant d'au moins un des espaces d'écoulement d'entrée (72, 74, 76, 80, 82, 146, 148, 216, 218) étant déchargés dans la chambre centrale (116), l'alimentation en hydrocarbures et les gaz de combustion passant sous forme de gaz tourbillonnants à travers le conduit convergent (48) jusqu'à la chambre de réaction (40).
  2. Le système de réacteur (12, 128, 198) selon la revendication 1, dans lequel :
    au moins un des espaces d'écoulement d'entrée annulaires (72, 74, 76, 80, 82, 146, 148, 216, 218) est pourvu d'aubes directrices (104, 106, 108, 110) espacées circonférentiellement les unes des autres et orientées de manière à faciliter l'écoulement tourbillonnaire du fluide à l'intérieur dudit au moins un des espaces d'écoulement d'entrée (72, 74, 76, 80, 82, 146, 148, 216, 218) ; et
    dans lequel, en option :
    les aubes directrices (104, 106, 108, 110) peuvent être déplacées vers des positions et des angles d'inclinaison sélectionnés afin d'obtenir des rapports de vitesse azimutale/radiale sélectionnés pour les fluides circulant dans les espaces d'écoulement d'entrée annulaires (80, 82, 146, 148, 216, 218) ;
    et/ou
    les aubes directrices (104, 106, 108, 110) sont configurées comme des profils aérodynamiques non plans.
  3. Le système de réacteur (12) selon l'une quelconque des revendications 1 ou 2, dans lequel :
    la paroi du réacteur (38) est cylindrique.
  4. Le système de réacteur (12, 128, 198) selon l'une quelconque des revendications 1 à 3, dans lequel :
    la paroi circonférentielle (50) du conduit convergent (48) depuis l'extrémité aval jusqu'à la portion de col rétréci annulaire (54), et éventuellement une partie amont de la paroi du réacteur (38) de la chambre de réaction (40) qui rejoint la paroi circonférentielle (50) du conduit convergent (48), est configurée comme une paroi lisse et continue qui suit les lignes de contour d'une calotte ellipsoïdale ou d'une calotte sphérique.
  5. Le système de réacteur (12, 128, 198) selon l'une des revendications 1 à 4, dans lequel :
    la paroi de séparation des gaz en aval (204) comporte une partie étendue (206) qui est espacée de la paroi circonférentielle (50) du conduit convergent (48) de l'ensemble d'entrée du réacteur (46) et en suit les contours, et se termine à une position en aval de la portion de col rétréci annulaire (54) de manière à définir un espace d'écoulement d'entrée en aval (208) qui se décharge dans une zone en aval de la portion de col rétréci annulaire (54).
  6. Le système de réacteur (12, 128, 198) selon l'une quelconque des revendications 1 à 5, dans lequel :
    au moins l'un parmi A et B, où dans lequel :
    A est l'espace d'écoulement d'entrée de gaz annulaire intermédiaire qui est divisé par une paroi intermédiaire de séparation des gaz (78) comportant une ouverture centrale (84) qui entoure l'axe central (52) du conduit convergent (48) et divise l'espace d'écoulement d'entrée intermédiaire (76) en espaces d'écoulement d'entrée annulaires intermédiaires en amont et en aval (72, 74, 76, 80, 82, 146, 148, 216, 218) qui constituent des espaces d'écoulement d'entrée convenant à l'introduction d'une charge de gaz combustible et d'une charge de comburant ; et
    B est l'espace d'écoulement d'entrée annulaire en amont (72) et l'espace d'écoulement d'entrée intermédiaire (76) constituent des espaces d'admission convenant à l'introduction d'une charge de gaz combustible et d'une charge de comburant.
  7. Le système de réacteur (12, 128, 198) selon l'une quelconque des revendications 1 à 6, comprenant en outre :
    un ensemble d'alimentation en gaz de refroidissement (154, 156) en communication fluidique avec au moins l'une des chambres de réaction (40) et l'ensemble d'entrée du réacteur (46), l'ensemble d'alimentation en gaz de refroidissement (154, 156) comprenant :
    une paire de parois (158, 160) de l'ensemble d'alimentation en gaz de refroidissement espacées axialement et orientées perpendiculairement ou sensiblement perpendiculairement à l'axe central (52), un espace annulaire d'écoulement d'entrée du gaz de refroidissement (162) étant défini entre les parois (158, 160) de l'ensemble d'alimentation en gaz de refroidissement et communiquant avec au moins l'une des chambres de réaction (40) et l'ensemble d'entrée du réacteur ; et
    dans lequel, en option :
    l'espace annulaire d'écoulement d'entrée du gaz de refroidissement (162) est pourvu d'aubes directrices (104, 106, 108, 110) espacées circonférentiellement et orientées de manière à faciliter l'écoulement tourbillonnant du fluide à l'intérieur dudit espace annulaire d'écoulement d'entrée du gaz de refroidissement (162).
  8. Un procédé de conversion d'hydrocarbures en oléfines, le procédé comprenant les étapes consistant à:
    introduire une charge d'hydrocarbures contenant des hydrocarbures à convertir dans un système de réacteur (12, 128, 198) selon l'une des revendications 1 à 7 et comprenant :
    une cuve de réacteur (36) comportant une paroi de réacteur (38) qui définit une chambre de réaction (40) ;
    un ensemble d'entrée de réacteur (46) couplé ou joint à une extrémité inférieure ou supérieure de la paroi du réacteur (38), l'ensemble d'entrée de réacteur (46) ayant un conduit convergent (48) avec une paroi circonférentielle (50) qui entoure un axe central (52) et s'étend à partir des extrémités opposées en amont et en aval du conduit convergent (48), la paroi circonférentielle (50) s'amincissant en largeur à partir des extrémités aval et amont jusqu'à une portion de col rétréci annulaire (54) située entre les extrémités aval et amont du conduit convergent (48), l'extrémité aval du conduit convergent (48) étant en communication fluidique avec la chambre de réaction (40) du réacteur (12, 128, 198), l'extrémité amont du conduit convergent (48) formant une entrée de l'ensemble d'entrée du réacteur (46) ;
    un ensemble d'alimentation (58, 130, 200) en communication fluidique avec l'entrée (56) de l'ensemble d'entrée du réacteur (46), l'axe central (52) traversant l'ensemble d'alimentation (58, 130, 200), l'ensemble d'alimentation comprenant :
    une paroi d'ensemble d'alimentation en aval (60) qui s'étend circonférentiellement autour de l'extrémité amont de l'ensemble d'entrée du réacteur (46) et la rejoint, la paroi d'ensemble d'alimentation en aval (60) étant orientée perpendiculairement ou sensiblement perpendiculairement à l'axe central (52) ;
    une paroi d'ensemble d'alimentation en amont (62) qui est axialement espacée en amont de la paroi d'ensemble d'alimentation en aval (60) le long de l'axe central (52) et qui s'étend perpendiculairement ou sensiblement perpendiculairement à travers l'axe central (52) ;
    une paroi de séparation des gaz en amont (64, 132, 202) perpendiculaire ou sensiblement perpendiculaire et une paroi de séparation des gaz en aval (66, 134, 204) perpendiculaire ou sensiblement perpendiculaire, qui sont chacune espacées axialement entre les parois d'ensemble d'alimentation en aval et en amont (60, 62) et qui sont axialement espacées l'une de l'autre, la paroi de séparation des gaz en amont (64, 132, 202) et la paroi de séparation des gaz en aval (66, 134, 204) étant orientées perpendiculairement ou sensiblement perpendiculairement à l'axe central (52), au moins l'une pami la paroi de séparation des gaz en amont (64, 132, 202) et la paroi de séparation des gaz en aval (66, 134, 204) se termine à une position en amont du conduit convergent (48) pour définir une ouverture centrale (68, 70, 84, 138, 140, 142, 214) qui entoure l'axe central (52) du conduit convergent (48), un espace d'écoulement d'entrée annulaire en amont (72) étant défini entre la paroi d'ensemble d'alimentation en amont (62) et la paroi de séparation des gaz en amont (64, 132, 202), un espace annulaire d'écoulement d'entrée en aval (74) étant défini entre la paroi d'ensemble d'alimentation en aval (60) et la paroi de séparation des gaz en aval (66, 134, 204), et un espace d'écoulement d'entrée intermédiaire (76) défini entre la paroi de séparation des gaz en amont (64) et la paroi de séparation des gaz en aval (66) ; dans lequel
    lesdits espaces d'écoulement d'entrée annulaires (72, 74, 76) amènent les flux introduits à s'écouler perpendiculairement ou sensiblement perpendiculairement vers l'axe central (52) du conduit convergent (48) dans un modèle d'écoulement de fluide tourbillonnant vers l'intérieur à l'intérieur desdits espaces d'écoulement autour de l'axe central (52) du conduit convergent (48) ; et dans lequel
    la zone s'étendant depuis l'ouverture centrale (68, 70, 84, 138, 140, 142, 214) d'au moins une des parois de séparation en amont et en aval (64, 132, 202, 66, 134, 204) jusqu'à l'entrée (56) de l'ensemble d'entrée du réacteur (46) définit une chambre centrale (116) de l'ensemble d'alimentation (58) ; et dans laquelle
    une charge d'hydrocarbures (14) à convertir est introduite dans un premier espace d'écoulement d'entrée (80, 146, 216) et une charge de gaz combustible (18) et une charge de comburant (16) sont introduites dans des deuxième (82, 148, 218) et troisième espaces d'écoulement d'entrée adjacents, de sorte que les charges traversent lesdits espaces d'écoulement perpendiculairement ou sensiblement perpendiculairement vers l'axe central (52) du conduit convergent (48) dans un modèle d'écoulement de fluide tourbillonnant vers l'intérieur à l'intérieur desdits espaces d'écoulement s'écoulant autour de l'axe central (52) du conduit convergent (48), la charge de gaz combustible (18) et la charge de comburant (16) brûlant dans la chambre centrale (116) pour former des gaz de combustion chauds, les gaz de combustion chauds et la charge d'hydrocarbures étant déchargés dans la chambre centrale et/ou la chambre de réaction (40) de sorte que les gaz de combustion chauds et les hydrocarbures soient mélangés et forment un mélange gazeux chauffé et tourbillonnant, les gaz plus denses s'écoulant plus près de la paroi du réacteur (38), tandis que les produits de combustion plus chauds ont tendance à s'écouler dans un flux de retour à travers le centre du réacteur ;
    laisser le mélange gazeux chauffé réagir dans la chambre de réaction (40) de la cuve du réacteur (36) dans des conditions de réaction permettant de convertir l'hydrocarbure en oléfines, une partie au moins de la charge d'hydrocarbures (14) du mélange gazeux étant convertie en produits d'oléfines ; et
    éliminer un produit d'oléfine de la chambre de réaction (40) de la cuve de réacteur (36).
  9. Le procédé selon la revendication 8, dans lequel :
    la charge de comburant (16) comprend un gaz contenant de l'oxygène (O2) et la charge de gaz combustible (18) comprend un gaz contenant de l'hydrogène composé d'au moins un gaz parmi le hydrogène gazeux (H2) et le méthane (CH4), le gaz contenant de l'oxygène étant introduit dans l'un des premier et second espaces d'écoulement d'entrée annulaire de gaz combustible (72, 74, 76, 80, 82, 146, 148, 216, 218) et le gaz contenant de l'hydrogène étant introduit dans l'autre ; et
    dans lequel, en option :
    le gaz contenant de l'hydrogène est introduit dans l'ensemble d'alimentation (58, 130, 200) pour fournir un excès d'hydrogène de 1 à 5 fois supérieur à celui nécessaire à la combustion de la charge de gaz combustible.
  10. Le procédé selon la revendication 8 ou 9, dans lequel :
    la charge d'hydrocarbures (14) comprend au moins l'un parmi l'éthane, le gaz de pétrole liquéfié, le butane, le naphta, le gaz naturel, les gazoles légers et les gazoles lourds, la charge d'hydrocarbures étant éventuellement prémélangée avec de la vapeur.
  11. Le procédé selon l'une des revendications 8 à 10, dans lequel :
    au moins l'un parmi le hydrogène gazeux (H2), le méthane et les oxydes de carbone formés pendant la réaction sont séparés du produit d'hydrocarbure oléfinique éliminé (22) et recyclés dans l'ensemble d'alimentation (58, 130, 200).
  12. Le procédé selon l'une des revendications 8 à 11, dans lequel :
    le rapport entre la vitesse azimutale et la vitesse radiale de chacune des charges et du flux d'alimentation en oxygène gazeux à l'intérieur des espaces d'écoulement annulaires est compris entre 0 et 30, la valeur 0 étant exclue.
  13. Le procédé selon l'une des revendications 8 à 12, dans lequel :
    au moins un des espaces d'écoulement d'entrée annulaires (72, 74, 76, 80, 82, 146, 148, 216, 218) est pourvu d'aubes directrices (104, 106, 108, 110) espacées circonférentiellement les unes des autres et orientées de manière à faciliter l'écoulement tourbillonnaire du fluide à l'intérieur dudit au moins un des espaces d'écoulement d'entrée (72, 74, 76, 80, 82, 146, 148, 216, 218).
  14. Le procédé selon l'une des revendications 8 à 13, dans lequel :
    le système de réacteur (20, 128, 198) comprend en outre un ensemble d'alimentation en gaz de refroidissement (154, 156) en communication fluidique avec au moins l'une des chambres de réaction (40) et l'ensemble d'entrée du réacteur (46), l'ensemble d'alimentation en gaz de refroidissement (154, 156) comprenant une paire de parois (158, 160) de l'ensemble d'alimentation en gaz de refroidissement espacées axialement orientées perpendiculairement ou sensiblement perpendiculairement à l'axe central (52), un espace annulaire d'écoulement d'entrée du gaz de refroidissement (162) étant défini entre les parois (158, 160) de l'ensemble d'alimentation en gaz de refroidissement et communiquant avec au moins l'une des chambres de réaction (40) et l'ensemble d'entrée du réacteur (46) où les gaz de refroidissement provenant de l'ensemble d'alimentation en gaz de refroidissement (154, 156) sont introduits.
  15. Le procédé selon l'une des revendications 8 à 14, dans lequel :
    le temps de séjour du mélange gazeux dans le système de réacteur (20, 128, 198) est inférieur ou égal à 50 millisecondes ; et/ou
    dans lequel :
    les conditions de réaction comprennent au moins une température comprise entre 900 °C et 1300 °C et une pression comprise entre 0 kPa (g) et 10 000 kPa (g) à une sortie du réacteur.
EP19877101.6A 2018-10-23 2019-10-23 Procédé et réacteur pour la conversion d'hydrocarbures Active EP3870353B1 (fr)

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WO2022010822A1 (fr) * 2020-07-06 2022-01-13 Sabic Global Technologies B.V. Procédé et réacteur destinés à la conversion d'hydrocarbures
WO2022010821A1 (fr) 2020-07-06 2022-01-13 Sabic Global Technologies B.V. Système de réacteur pour la production de produits chimiques à valeur élevée
WO2022010823A1 (fr) * 2020-07-06 2022-01-13 Sabic Global Technologies B.V. Procédé et réacteur pour la conversion d'hydrocarbures
EP4305130A1 (fr) * 2021-03-12 2024-01-17 SABIC Global Technologies B.V. Procédés de séparation pour produits de pyrolyse de réacteur à chambre de turbulence à jet annulaire
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EP3870353A4 (fr) 2021-12-15
MX2021004563A (es) 2022-06-22
EP4400563A3 (fr) 2025-04-02
EP3870353A2 (fr) 2021-09-01
MX393323B (es) 2025-03-24
CN113195092A (zh) 2021-07-30
WO2020086681A2 (fr) 2020-04-30
EP4400563A2 (fr) 2024-07-17
CN113195092B (zh) 2022-04-29
US20210308650A1 (en) 2021-10-07
RU2761844C1 (ru) 2021-12-13
US11123705B1 (en) 2021-09-21

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